Fabric welding machine

ABSTRACT

Methods and other embodiments associated with a fabric welding machine are presented. The fabric welding machine includes a base, a welding machine body, and a support beam with a first end and a second end. A first roller is positioned adjacent to the first end of the support beam opposite the welding machine body. A swing arm with a body end and a roller end is attached to the welding machine body. The roller end is opposite the welding machine body and is configured to move to a first position and a second position. A heat element attached to the first end of the support beam.

BACKGROUND

1. Technical Field

The present invention relates generally to seaming machines. Moreparticularly, the invention relates to a seaming machine and method ofproducing a seeming machine. Specifically, the invention relates to aseeming machine with a swing arm that is configured to be positioned ina plurality of positions and that has a detachable fabric table.

2. Background Information

A larger sheet of material is created by joining two sheets of materialtogether at their seams. Typically, a first segment of sheet material islaid on a table or other work surface and a second segment of sheetmaterial is positioned above the first segment with their edgesgenerally aligned so that a seaming device moves along the aligned edgesto form a seam along the length of the two sheet segments. Thistypically results in a two-segment sheet which is roughly twice as largeas each of the individual segments. In order to form larger sheets ofmaterial, additional segments of sheet material must be sequentiallyseamed together. This seaming process may be achieved by various seamingdevices depending on the material from which the sheets are formed andthe application for which the product will be used. For example, seamsmay be formed using plastic welders, ultrasonic welders, radio frequency(RF) welders, adhesive or glue seaming devices or sewing devices amongstothers.

As will be appreciated, the larger the sheet becomes, the more unwieldyit is to handle. The standard practice for adding one or more additionalsegments of sheet material to the two-segment sheet is to slide one ofthe sheet segments off of a table or work surface and move thenon-seamed edge of the other sheet segment adjacent the side of thetable along which the seaming device is positioned. Especially duringthe formation of larger sheets of material such as relatively heavytarps, the movement of these sheet segments and re-positioning thereofcan be difficult for a single operator of the seaming device. Once thenon-seamed edge of the second segment of sheet material is properlypositioned, a third segment of sheet material is positioned adjacent thesecond segment and the edges of the second and third segments are thenseamed together.

A table or work surface may be helpful to manipulated sheets of materialseemed to produce a generally flat result. However, sliding material ona seaming machine table may make it difficult to produce cylindrical,elliptical, oval, spherical, and other curved shapes. Additionally,after each segment of sheet material is seamed to the previous one,additional sheet material must be moved off of the table or work surfaceand gradually piles up on the floor, often in disarray. Furthermore,material hanging off of the table or an elevated work surface pulls onthe material atop the table and adds to the difficulty of aligning thematerial for a subsequent seaming operation. In short, the process isrelatively time consuming and labor intensive. A better way of joiningfabric is desired.

BRIEF DESCRIPTION OF THE DRAWINGS

One or more preferred embodiments that illustrate the best mode(s) areset forth in the drawings and in the following description. The appendedclaims particularly and distinctly point out and set forth theinvention.

The accompanying drawings, which are incorporated in and constitute apart of the specification, illustrate various example methods, and otherexample embodiments of various aspects of the invention. It will beappreciated that the illustrated element boundaries (e.g., boxes, groupsof boxes, or other shapes) in the figures represent one example of theboundaries. One of ordinary skill in the art will appreciate that insome examples one element may be designed as multiple elements or thatmultiple elements may be designed as one element. In some examples, anelement shown as an internal component of another element may beimplemented as an external component and vice versa. Furthermore,elements may not be drawn to scale.

FIG. 1 illustrates a perspective view of an embodiment of a fabricwelding machine used to weld two fabrics together.

FIGS. 2 and 3 illustrate side views of an embodiment of a fabric weldingmachine with a post arm in a vertical position.

FIG. 4 illustrates a perspective side view of an embodiment of fabricwelding machine with a post arm in a horizontal position.

FIGS. 5 and 6 illustrate side views of an embodiment of a fabric weldingmachine with a post arm in a horizontal position.

FIG. 7 illustrates a cross-sectional view of an embodiment of a fabricwelding machine.

FIG. 8 illustrates an exploded view of an embodiment of a fabric weldingmachine with a fabric table being attached to the fabric weldingmachine.

FIG. 9 illustrates a side view of an embodiment of a fabric weldingmachine with a fabric table being attached to the fabric weldingmachine.

FIG. 10 illustrates a side view of an embodiment of a fabric weldingmachine with a fabric table attached to the fabric welding machine.

FIG. 11 illustrates a detailed cross-sectional side view of anembodiment of a fabric welding machine with a fabric table attached tothe fabric welding machine.

FIG. 12 illustrates a back view of an embodiment of a fabric weldingmachine with a fabric table attached to the fabric welding machine.

FIG. 13 illustrates a detailed side view of an embodiment of a fabricwelding machine with a fabric table attached to the fabric weldingmachine.

FIG. 14 illustrates a perspective view of an embodiment of a fabricwelding machine with a fabric table attached to the fabric weldingmachine.

FIG. 15 illustrates a perspective view of an embodiment of a fabricwelding machine without a fabric table attached to the fabric weldingmachine showing the fabric welding machine in operation with the postarm in a vertical position.

FIG. 16 illustrates a perspective view of an embodiment of a fabricwelding machine without a fabric table attached to the fabric weldingmachine showing the fabric welding machine in operation with a post armin a horizontal position.

FIG. 17 illustrates a perspective view of an embodiment of a fabricwelding machine with a fabric table attached to the fabric weldingmachine showing the fabric welding machine in operation.

FIG. 18 illustrates a side view of an embodiment of a fabric weldingmachine with a fabric table attached to the fabric welding machineshowing fabric passing between rollers.

FIG. 19 illustrates an embodiment of a method associated with a fabricwelding machine.

Similar numbers refer to similar parts throughout the drawings.

DETAILED DESCRIPTION OF THE INVENTION

FIG. 1 illustrates a preferred embodiment of a welding machine 10 usedto weld together two pieces of fabric. In the preferred embodiment, thewelding machine 10 is configured with either a hot air 12 or a hot wedgeheating system. These heating systems generate and apply heat to theseams of two pieces of fabric 15, 16 to connect the two pieces of fabric15, 16 together as they are moved in direction “C” as shown in FIG. 15.In the preferred embodiment, a hot wedge heating system is configured toproduce heat up to 450 degrees Celsius and a hot air heating system 12is configured to produce heat up to 750 degrees Celsius. The figuresillustrate a welding machine 10 with a hot air heating system 12 thatapplies heated hot air through a nozzle 14, however, a hot wedge orother welding device could be attached to the welding machine 10. Thewelding machine 10 is capable of welding a variety of materialsincluding polyvinyl chloride (PVC), polyurethane (PU), polyolefins(PEs), as well as many other materials.

Before describing the figures in detail, the figures are introduced thathighlight why the welding machine 10 is an improvement over traditionalwelding machines for a variety of reasons. For example, FIG. 1 shows thewelding machine 10 includes a swing arm 1 that can be positioned in atleast two different positions. The swing arm 1 may be U-shaped with aroller end 5 and a body end 4. The details of the shape of the swing arm1 will be discussed in detail later with respect to FIGS. 3 and 4. Inone embodiment, the roller end 5 may be the end of a post arm 3 of theswing arm 1. A roller may be attached at the roller end 5. FIGS. 1, 3and 13-15 show the post arm 3 positioned in a vertical position. FIGS.4, 5, 8 and 16 show the post arm 3 rotated in a direction “A” toreconfigure the swing arm 1 to a horizontal position. Positioning thepost arm 3 in a vertical position may facilitate the welding of sheetsof material as shown in FIG. 15. Positioning the post arm 3 in ahorizontal position may facilitate the welding of conical sections offabric as the fabric is moved in direction “D” as shown in FIG. 16.

In the preferred embodiment, a fabric table 7 may be easily attached toand removed from the welding machine 10. FIG. 14 shows the fabric table7 attached to the welding machine 10 when the post arm 3 of the swingarm 1 is in a vertical position. FIGS. 17 and 18 illustrate how thefabric table 7 aids in the welding of two sheets of fabric 15, 16 whenthe fabric 15, 16 is moved in direction “E”. In another embodiment, asecond table may be attached to or positioned near the rear of thewelding machine 10 to receive fabric that has been welded by the weldingmachine 10. The fabric table 7 is generally used to produce straightseams for produces such as tarps, awning and tents; while the swing arm1 is generally used to form curves and unique shapes for products likeboats and inflatables.

As previously mentioned, the swing arm 1, is generally U-shaped as shownin FIG. 4. The post arm 3 and a first arm 88 of the swing arm 1 form theside of the U-shape and a middle portion 2 of the swing arm 1 forms thebottom of the U-shape. The post arm 3 and first arm 88 are parallel eachother but pointing in two slightly different directions. When the middleportion 2 is in a lowered position, n the post arm is in a verticalposition as best seen in FIG. 3. In this position, the first arm 88 isgenerally vertical but can be seen at a significantly different anglethan the post arm 3. This is because the post arm 3 is connected to themiddle portion 2 with a spacing member while the first arm 88 isconnected to the middle portion 2 without a spacing member.

A U-shaped swing arm 1 that is also movable allows for a variety ofmaterials to welding by the welding machine. For example, when the postarm 3 is vertical and the fabric table is not attached, the weldingmachine 10 can weld round shaped fabric that can be draped over the topof the post arm 3 as shown in FIG. 16. The U-shape provides an open areawhere fabric and/or an operator of the fabric machine may be positionedat during welding operations. When the post arm is horizontal and thefabric table is not attached, fabric can be draped over the middleportion 2 while fabric is being welded. This configuration may also beuseful for welding cylindrical shapes as shown in FIG. 16. As previouslymentioned, when the fabric table 7 is attached, the fabric table isuseful to produce straight flat seams.

Returning to FIG. 1, this figure shows the welding machine 10 includesbase 18, a welding machine body 20 with a top 21 and a bottom 22. Thebottom 22 of the welding machine body 20 is attached to one end of thebase 18. The base 18 may include wheels 23 to allow the welding machine10 to be moved to different locations. The welding machine 10 includes asupport beam 24 with a first end 25 and a second end 26. The second 6end is attached to the top 21 of the welding machine body 20.

In general, the base 18, welding machine body 20 and the support beam 24form a frame of the welding machine 10. In this preferred embodiment,this frame is connected together to form a rigid steel frame. The swingarm 1 may also be fabricated out of steel components to ensure thewelding machine 10 is solid and durable. The swing arm 1 may bepartially fabricated out of steel tubular sections of pipe. The post arm3 section of the swing arm 1 may be fabricated out of an elongatedsection of steel with a rectangular cross-section.

In the preferred embodiment, the welding machine 10 includes a controlsystem with a graphical user interface (GUI) 28. The GUI 28 ispositioned in the support beam 24 to allow an operator of the weldingmachine 10 to easily see and enter values into the GUI 28. The GUI 28allows an operator of the welding machine 10 to select a temperature ofthe heating system 12, select a roller speed of rollers used to pullfabric through the welding machine 10, as well as other settings. Thecontrol system can store parameter settings for multiple configurationsof the welding machine 10 so that the parameters do not need to becompletely re-entered each time a particular configuration is needed.The GUI 28 may present prompts in one of several different languagesthat is selected by an operator. An emergency stop button 30 and a poweron/of button 32 may be located adjacent the GUI 28. One or more footpeddles 34 may be attached to the welding machine 10 to allow anoperator to control when heat is applied or when rollers are driven topropel fabric through the welding machine 10.

Adjacent the heat system 12 and also mounted on the first end 25 of thesupport beam 24 are two rollers 38, 39 that are best seen in FIG. 13.One or both rollers 38, 39 may be driven by a roller driver 42. Theroller driver 42 will drive the rollers so that fabric can be processedthrough the welding machine 10 at a rate of up to 50 meters per minute.As previously mentioned, an operator can set the roller speed throughGUI 28. A variety of adjustment devices 27 are also mounted on thesupport beam 24 to facilitate an operator in adjusting the positioningof the rollers 38, 39 and in adjusting how much pressure the rollers 38,39 exert on each other. The adjustment devices also facilitate anoperator in controlling how much pressure is applied to fabric movingbetween roller 39 and a roller 40 mounted to the roller end 5 of theswing arm 1.

The first end 25 of the support beam 24 is also configured to be fittedwith various guides (not shown) to assist an operator of the weldingmachine 10 with aligning two sheets of material to be welded together.The different guides can assist an operator with making a variety ofspecific seams. For example, the welding machine 10 is configured to befitted with guides to create weld hems, overlaps, hem with rope, hemwith pocket, as well as other seams.

FIGS. 2 and 3 illustrate the welding machine 10 configured with themiddle portion 2 of the swing arm 1 in down position so that the postarm 3 of the swing arm 1 is in a vertical position. A bracket 44 ispivotally attached by a pin fastener 46 to the end of the middle portion2 adjacent the welding machine body 20. The welding machine 10 isconfigured to allow the post arm 3 to be mounted in a vertical positionby attaching a grooved end 47 of the bracket 44 to a first knob 45mounted on the welding machine body 20. The welding machine 10 isfurther configured to allow the post arm 3 to be mounted in a horizontalposition by attaching a grooved end 47 of the bracket 44 to a secondknob 49 mounted on the welding machine body 20 as shown in FIGS. 4 and5. Notice the second knob 49 has a lower profile than the first knob 45to allow the bracket to pass over the second knob 49.

FIG. 7 illustrates how in the preferred embodiment the swing arm 1 ismounted to the welding machine body 20. A pipe attachment portion 51 ofthe swing arm 1 is positioned through a hole 52 in side walls 50 andpasses through a first bushing 53 and a second bushing 54. The firstbushing 53 and the second bushing 54 may have different lengths and mayeach be lined with a bushing liner 55, 56. The bushing liners 55, 56 areformed with a material that allows the swing arm 1 to easily rotatewithin the first bushing 53 and the second bushing 54. The first busing53 and the second bushing 54 attached to the side walls 50 withfasteners that may be bolts 58. Two stops 57 may be attached to the pipeattachment portion 52 to prevent the swing arm 1 from sliding out of orfurther into the welding machine body 20. The pipe attachment portion 52may be configured with a rod 59 to facilitate the pivotal movement ofthe pipe attachment portion 52 around an axis 60. The side walls 50 maybe formed with steel sections that are hollow in the middle.

FIGS. 8-12 show how the fabric table 7 is attached to the weldingmachine 10. The fabric table 7 is attached to the post arm 3 of theswing arm 1 and the welding machine body 20 when the middle portion 2 ofthe swing arm 1 is in a lowered position. The fabric table 7 includes arear roller 63 and a front roller 64 to aid the movement of fabricacross the fabric table 7. An elevated portion 62 of the fabric table 7allows the fabric table 7 to be fitted over the pipe attachment portion51 of the swing arm 1. A mounting flange 61 with two screw holes 66 ismounted on one side of the fabric table 7 and a mounting flange 71 withtwo slots 68 is mounted to the other side of the fabric table 7. Thefabric table 7 is configured to attach to the post arm 3 of the swingarm 1 by passing two screws 65 through two screw holes 66 in themounting flange 61 and then attaching the screws 65 to the post arm 3.The screw holes 66 may be elongated in the horizontal position to aid inthe aligning of the holes 66 with complementary threaded holes 72 in thepost arm 3. The fabric table 7 is configured move in a downwarddirection “B” (see FIG. 10) so the fabric table 7 can be attached to thewelding machine body 20 by sliding two slots 68 onto two knobs 67 (e.g.,thumb screws) that are mounted on the welding machine body 20. The knobs67 may include a threaded portion 69 as shown in FIG. 11. The knobs 67can be tightened after the fabric table 7 is resting on the loosenedknobs 67. In the preferred embodiment, the knobs 67 may pass through asupport plate 70 attached to the side of the welding machine body 20 andthe knobs may be tightened in a threaded portion 73 of the support plate70 to press the mounting flange 71 against the support plate 70.

FIG. 13 illustrates a detailed view of the rear roller 63 of the fabrictable 7 and the other three rollers 38, 39, 40 when the fabric table 7is attached to the welding machine10. Fabric 15, 16, is initially pulledby rollers 39, 40 while the fabric is heated by the hot air nozzle 14.These rollers 39, 40 apply the correct pressure to the seam so that astrong seam is created between the two fabrics 16, 15. Rollers 42, 63will continue to pull that fabric 15, 16 after the fabric has beenwelded. FIG. 18 shows how two sheets of fabric 15, 16 are passed throughthe welding machine 10 when the fabric table 7 is attached. This Figurealso shows how the fabric 15, 16 is positioned when an overlapping jointbetween the two sheets of fabric 15, 16 is being created by moving thefabric 15, 16 in direction “E”. In FIG. 18, roller 28 rotates as shownby direction “F” and roller 38 rotates as shown by direction “G”.

Example methods may be better appreciated with reference to flowdiagrams. While for purposes of simplicity of explanation, theillustrated methodologies are shown and described as a series of blocks,it is to be appreciated that the methodologies are not limited by theorder of the blocks, as some blocks can occur in different orders and/orconcurrently with other blocks from that shown and described. Moreover,less than all the illustrated blocks may be required to implement anexample methodology. Blocks may be combined or separated into multiplecomponents. Furthermore, additional and/or alternative methodologies canemploy additional, not illustrated blocks.

FIG. 19 illustrates an embodiment of a method 200 associated withoperating a welding machine to weld a first fabric sheet to a secondfabric sheet. As mentioned earlier, the welding machine may weld avariety of fabrics including a variety of polymers. For example, themachine may weld fabrics containing polyvinyl chloride (PVC),polyurethane (PU), polyolefins (PEs) and other polymers using a heatsource. The method 200 begins, at 202, by moving a swing arm of thefabric welding machine to a first position. The swing arm is configuredto be set up in a first position or a second position. The swing arm maybe U-shaped and may be pivotally attached to the fabric welding machine.The fabric welding machine is then operated to connect a first fabricsheet to a second fabric sheet at 204.

In another embodiment, the method attaches a fabric table to the fabricwelding machine. The fabric welding table has a flat surface that aidsin the movement and positioning of fabric to be connected. The fabrictable is attached to the fabric welding machine by sliding one or moregrooves in the fabric table onto one or more knobs on the fabric weldingmachine. The fabric table is configured to attach to the swing arm bypushing one or more connectors through the fabric table and attachingthe one or more connectors into the swing arm.

A person of ordinary skill in the art will realize that even thoughspecific numbers of devices such as screws or bolts are shown in thefigures, that in other embodiments different numbers (e.g., less ormore) of the same device may be used. A person of ordinary skill in theart will also realize that even though specific devices such asfastening devices (e.g., bolts) are shown in the figures that otherdevices may be used as fastening devices. For example, in one embodimentone screw may be used to attach the fabric table 7 to the post arm 3rather than the two screws 65 shown in FIG. 8.

In the foregoing description, certain terms have been used for brevity,clearness, and understanding. No unnecessary limitations are to beimplied therefrom beyond the requirement of the prior art because suchterms are used for descriptive purposes and are intended to be broadlyconstrued. Therefore, the invention is not limited to the specificdetails, the representative embodiments, and illustrative examples shownand described. Thus, this application is intended to embracealterations, modifications, and variations that fall within the scope ofthe appended claims.

Moreover, the description and illustration of the invention is anexample and the invention is not limited to the exact details shown ordescribed. References to “the preferred embodiment”, “an embodiment”,“one example”, “an example”, and so on, indicate that the embodiment(s)or example(s) so described may include a particular feature, structure,characteristic, property, element, or limitation, but that not everyembodiment or example necessarily includes that particular feature,structure, characteristic, property, element or limitation. Furthermore,repeated use of the phrase “in the preferred embodiment” does notnecessarily refer to the same embodiment, though it may.

1. A welding machine comprising: a welding machine body; a support beamwith a first end and a second end, wherein the second end is attached tothe welding machine body; a first roller positioned adjacent to thefirst end of the support beam; a swing arm with a body end and a rollerend, wherein the body end is attached to the welding machine body,wherein the roller end is configured to move to a first position and asecond position; and a heat element attached to the first end of thesupport beam.
 2. The welding machine of claim 1, further comprising: afabric table removably attached to the welding machine body and theswing arm when the roller end of the swing arm is in a substantiallyvertical position.
 3. The welding machine of claim 2, furthercomprising: one or more posts on the welding machine body; and one ormore grooves in the fabric table, wherein the fabric table is configuredto be attached to the welding machine body by sliding the one or moregrooves onto the one or more posts.
 4. The welding machine of claim 2,further comprising: a fabric table roller spanning a majority of alength of a back end of the fabric table, wherein the fabric tableroller is attached the fabric table.
 5. The welding machine of claim 1,wherein the swing arm is U shaped.
 6. The welding machine of claim 1,wherein the swing arm is pivotally attached to the welding machine body,and wherein the swing arm is configured to pivot between the firstposition and the second position.
 7. The welding machine of claim 6,further comprising: a second roller attached to the roller end of theswing arm; and an axis, wherein the swing arm pivots around the axis andthe second roller pivots around the axis.
 8. The welding machine ofclaim 1, further comprising: a first knob and a second knob attached thewelding machine base; a support arm pivotally attached the swing arm;and a groove at an attachment end of the support arm, wherein the grooveis configured to slide onto the first knob when the swing arm is in thefirst position, and wherein the groove is configured to slide onto thesecond knob when the swing arm is in the second position.
 9. The weldingmachine of claim 1, wherein the first roller is configured to bepropelled at a user selected speed, and wherein the first roller ispropelled when the user steps on a foot peddle electrically connected tothe welding machine.
 10. The welding machine of claim 1, wherein whenthe swing arm is in the first position the roller end is substantiallyvertical and when the swing arm is in the second position the roller endis substantially horizontal.
 11. The welding machine of claim 1, furthercomprising: a second roller attached to the roller end, wherein thesecond roller is adjacent the first roller when the swing arm is in thefirst position or the second position;
 12. A welding machine comprising:a welding machine body; a welding arm with an end extending away fromthe welding machine body; a first roller attached to the welding arm endextending away from the welding machine body; and a fabric tableconfigured to be removably attached to the welding machine.
 13. Thewelding machine of claim 12, further comprising: a base with a verticalpost, wherein the welding machine body is on the base, wherein thefabric table is removably attached to the vertical post and removablyattached to the welding machine body.
 14. The welding machine of claim12 further comprising: one or more knobs on the welding machine body;and one or more grooves in the fabric table, wherein the fabric table isconfigured to be attached to the welding machine body by sliding the oneor more grooves onto the one or more knobs.
 15. A method of operating afabric welding machine comprising: moving a swing arm of the fabricwelding machine to a first position, where the swing arm is configuredto be set up in a first position and a second position; and operatingthe fabric welding machine to connect a first fabric sheet to a secondfabric sheet.
 16. The method of claim 15, further comprising: attachinga fabric table to the fabric welding machine; and operating the fabricwelding machine to connect a third fabric sheet to a fourth fabricsheet.
 17. The method of claim 16, wherein the fabric table is attachedto the fabric welding machine by sliding one or more grooves in thefabric table onto one or more knobs on the fabric welding machine,wherein the fabric table is configured to attach to the swing arm withone or more connectors.
 18. The method of claim 17, further comprising:moving the swing arm to a second position; and operating the fabricwelding machine to connect a third fabric sheet to a fourth fabricsheet.
 19. The method of claim 15, wherein the swing arm is moved to afirst position by pivoting the swing arm to the first position.
 20. Themethod of claim 15, wherein the swing arm is moved to the first positionby attaching a support bracket pivotally attached to the swing arm to afirst knob, and wherein the support arm is moved to a second position byattaching the support bracket to a second knob.